The application of Ultra-High-Performance Concrete (UHPC) materials in rehabilitating bridges and constructing primary bridge components is increasing rapidly across the world because of their superior strength and durability characteristics when compared to regular concretes. However, there have been few new bridges constructed using UHPC materials with regular formworks, ready-mix trucks, and construction equipment. This paper presents a comprehensive report encompassing the design, construction, and performance monitoring of a new bridge constructed in Iowa using a unique UHPC technology that includes steel fibers of two different lengths embedded in the concrete. By using optimized lengths of steel fibers, both the tensile strength and the toughness were increased. The UHPC material was produced with local cement and aggregates in the US using typical ready-mix concrete equipment. This paper discusses the experience gained from the design and construction process including mix design, batching, delivery of steel fibers to the ready-mix concrete batch unit, and post-tensioning of precast slabs at the jobsite. For four years after construction, the joints of the bridge decks were monitored using strain sensors mounted on both sides of the deck joints. The strain values were quite similar between the two sides of each joint, indicating a good load transfer between precast bridge girders. A bridge was successfully constructed using a unique UHPC technology incorporating two different lengths of steel fibers and utilizing local cement and aggregates and a ready-mix truck, and has been performing satisfactorily with a good load transfer across post-tensioned precast girder joints.

Cold In-place Recycling (CIR) has been widely used in the world since it is easy to apply it in the field at a low cost. However, it is not normally used as a surface layer as a result of its inconsistent quality due to an excessive amount of fine aggregates pulverized during the milling process. Hot In-place Recycling (HIR) can retain the original shape of the aggregates, but it often produces a large amount of Volatile Organic Compounds (VOCs). Therefore, a third in-place recycling technique is introduced in this paper: Warm In-place Recycling (WIR). The WIR technique overcomes the limitations of both CIR and HIR techniques by lowering a heating temperature while adding a Tetraethylenepentamine (TEPA)/Soybean/SBS additive. To identify the effect of the additive on the RTFO-aged binder, viscosity and dynamic modulus values were measured at different temperatures. Based on Hamburg Wheel Tracking (HWT) and Disc-Shaped Compact Tension (DCT) tests, the additive improved the moisture susceptibility and low temperature cracking resistance. The indirect infrared heating equipment reduced the emission by lowering the pavement surface heating temperature by 20 °C from 140 to 120 °C. Compared with the heating at 140 °C, the LPG usage for heating at 140 °C was lowered by 21%. The proposed WIR equipment with an additive would revolutionize the in-place recycling practices.

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